Comparative Study of Mechanical Properties and Microstructure Between Conventional and Infinite z-Axis Fused Deposition Modeling Printers

Additive Manufacturing (AM) has emerged as a critical technology in shaping manufacturing strategies, offering versatility and efficiency in designing complex structural components. Extensive literature exists on small- to mid-sized product production. However, a significant knowledge gap exists in manufacturing elongated products, such as wind turbine blades and constructional beams. Current AM technology faces limitations in this context, primarily due to the constraints imposed by the conventional 90-degree nozzle head and limited bed space. This study introduces an innovative AM approach called Infinite z-Axis Printing. This novel technique utilizes a belt-driven heated bed and a 45-degree nozzle head to 3D print objects of infinite length. The study compares this groundbreaking approach and the traditional 90-degree nozzle head Fused Deposition Modeling (FDM) method and the associated results. The findings of this research demonstrate that the Infinite z-Axis Printing methodology yields a significant improvement of up to 20% in tensile and compressive strength compared to the currently used FDM process. This advancement can potentially revolutionize on-site operations by enabling the efficient production of elongated structural components, thus contributing significantly to the construction and renewable energy sectors.